Bearing system for observation wheels

ABSTRACT

Systems and related methods related to structures with large-scale rotatable elements. Some of the present systems comprise: a tower; a tower hub coupled to the tower and having a transverse dimension of at least 50 feet; an observation wheel rotatably coupled to the tower and having a central wheel hub; a plurality of roller bearings disposed between the tower hub and the wheel hub to rotatably support the observation wheel relative to the structure, the roller bearings each having a diameter that is less than one quarter of the transverse dimension of the wheel hub.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 14/826,725, filed Aug. 14, 2015, which is a continuation ofU.S. patent application Ser. No. 14/191,071, filed Feb. 26, 2014, whichclaims the benefit of U.S. Provisional Patent Application No. 61/769,359filed Feb. 26, 2013, each of which applications is hereby incorporatedby reference.

FIELD OF INVENTION

The present invention is generally related to large structures such asobservation wheels and more particularly, but not by way of limitation,to a rolling-element bearing system and/or other features andimprovements for large structures such as observation wheels.

BACKGROUND

Observation wheels such as the London Eye and subsequent wheels, such asthe Singapore Flyer and the Star of Nanchang, contain two giant rollingelement bearings in the center hub of the wheel. These giant bearingsrequire a giant seal to encompass the bearing in order to hold inlubricant. When utilizing giant bearings in an observation wheel, thefact that components can only be produced to a certain size becomes aconstraint on the overall size of the attraction. The engineeringconsiderations that are present in the design of such large systems arematerially different than those that exist with respect to smallersystems.

SUMMARY

At least some of the present embodiments provide and/or include animproved bearing system for a large system such as an observation wheelthat reduces and/or eliminates the size constraints that are generallyassociated with larger conventional bearings.

Some embodiments of the present systems comprise: a tower; a tower hubcoupled to the tower and having a transverse dimension of at least 50feet; an observation wheel rotatably coupled to the tower and having acentral wheel hub; a plurality of roller bearings disposed between thetower hub and the wheel hub to rotatably support the observation wheelrelative to the structure, the roller bearings each having a diameterthat is less than one quarter of the transverse dimension of the wheelhub. In some embodiments, the tower includes a base and a height of atleast 200 feet above a ground level at the base, and the observationwheel having a transverse dimension of at least 400 feet. In someembodiments, the tower is a first tower, and the system furthercomprises: a second tower spaced apart from the first tower and coupledto the tower hub; where the tower hub extends between the first andsecond towers. Some embodiments further comprise: a plurality of bearingmounts each coupled to a different one of the roller bearings. In someembodiments, the plurality of bearing mounts each has a first endcoupled in fixed relation to the tower hub and a second end rotatablycoupled to the respective roller bearing. In some embodiments, the wheelhub has a first diameter, the tower hub has a second diameter that issmaller than the first diameter, and the wheel hub is configured torotate around the tower hub. In some embodiments, each of the pluralityof roller bearings has a diameter of between 0.5 and 5 feet. In someembodiments, the diameter of the tower hub differs from the diameter ofthe wheel hub by 4 feet or more. In some embodiments, the diameter ofthe tower hub is greater than 70 feet. In some embodiments, each of theplurality of roller bearings is independently sealed.

Some embodiments of the present methods comprise: disposing a pluralityof bearings between a tower hub and an observation wheel rotatablycoupled to the tower, the tower hub coupled to a tower and having atransverse dimension of at least 50 feet, and the observation wheelhaving a central wheel hub; where the roller bearings are disposedbetween the tower hub and the wheel hub to rotatably support theobservation wheel relative to the structure, the roller bearings eachhaving a diameter that is less than one quarter of the transversedimension of the wheel hub. In some embodiments, the tower includes abase and a height of at least 200 feet above a ground level at the base,and the observation wheel having a transverse dimension of at least 400feet. In some embodiments, the tower is a first tower, a second tower isspaced apart from the first tower and coupled to the tower hub, and thetower hub extends between the first and second towers. In someembodiments, a plurality of bearing mounts are each coupled to adifferent one of the roller bearings. In some embodiments, the pluralityof bearing mounts each has a first end and a second end rotatablycoupled to the respective roller bearing, and disposing the rollerbearings comprises coupling the first end of each roller bearing infixed relation to the tower hub. In some embodiments, the wheel hub hasa first diameter, the tower hub has a second diameter that is smallerthan the first diameter, and the wheel hub is configured to rotatearound the tower hub. In some embodiments, each of the plurality ofbearing elements has a diameter of between 0.5 and 5 feet. In someembodiments, the diameter of the tower hub differs from the diameter ofthe wheel hub by 4 feet or more. In some embodiments, the diameter ofthe tower hub is greater than 70 feet. In some embodiments, each of theplurality of roller bearings is independently sealed.

The term “coupled” is defined as connected, although not necessarilydirectly, and not necessarily mechanically; two items that are “coupled”may be unitary with each other. The terms “a” and “an” are defined asone or more unless this disclosure explicitly requires otherwise. Theterm “substantially” is defined as largely but not necessarily whollywhat is specified (and includes what is specified; e.g., substantially90 degrees includes 90 degrees and substantially parallel includesparallel), as understood by a person of ordinary skill in the art. Inany disclosed embodiment, the terms “substantially,” “approximately,”and “about” may be substituted with “within [a percentage] of” what isspecified, where the percentage includes 0.1, 1, 5, and 10 percent.

Further, a device or system that is configured in a certain way isconfigured in at least that way, but it can also be configured in otherways than those specifically described.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”), and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, anapparatus that “comprises,” “has,” “includes,” or “contains” one or moreelements possesses those one or more elements, but is not limited topossessing only those elements. Likewise, a method that “comprises,”“has,” “includes,” or “contains” one or more steps possesses those oneor more steps, but is not limited to possessing only those one or moresteps.

Any embodiment of any of the apparatuses, systems, and methods canconsist of or consist essentially of—rather thancomprise/include/contain/have—any of the described steps, elements,and/or features. Thus, in any of the claims, the term “consisting of” or“consisting essentially of” can be substituted for any of the open-endedlinking verbs recited above, in order to change the scope of a givenclaim from what it would otherwise be using the open-ended linking verb.

The feature or features of one embodiment may be applied to otherembodiments, even though not described or illustrated, unless expresslyprohibited by this disclosure or the nature of the embodiments.

Some details associated with the embodiments described above and othersare described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate by way of example and not limitation.For the sake of brevity and clarity, every feature of a given structureis not always labeled in every figure in which that structure appears.Identical reference numbers do not necessarily indicate an identicalstructure. Rather, the same reference number may be used to indicate asimilar feature or a feature with similar functionality, as maynon-identical reference numbers. The figures are drawn to scale (unlessotherwise noted) for at least the embodiments shown.

FIG. 1 is a perspective view of one of the present systems.

FIG. 2 is a top view of the system of FIG. 1.

FIG. 3 is an front view of the system of FIG. 1.

FIG. 4 is a side view of the system of FIG. 1.

FIG. 5 is a perspective view of a portion of the system of FIG. 1.

FIG. 6 is a fragmentary perspective view of a bearing subsystem of thesystem shown in FIG. 1.

FIGS. 7A and 7B are side and front views, respectively, of a rollerbearing assembly of the bearing subsystem shown in FIG. 6.

FIG. 8A is an exploded perspective view of part of a tower hub portionof the system of FIG. 1.

FIG. 8B is a side view of the part of the tower hub portion shown inFIG. 7A.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring now to the drawings, and more particular to FIGS. 1-4, shownthere and designated by the reference numeral 10 is one example of thepresent systems. In the embodiment shown, system 10 is an observationwheel system. In the embodiment shown, system 10 comprises a first tower14 a and a second tower 14 b, a tower hub 18 coupled to and extendingbetween first and second towers 14 a and 14 b. Tower hub 18 can, in someembodiments, have a transverse dimension of at least 50 feet (e.g.,greater than 70 feet). For example, in the embodiment shown, tower hub18 has a diameter of 80 feet. In the embodiment shown, system 10 alsocomprises an observation wheel 22 rotatably coupled to the towers andhaving a central wheel hub 26. In the embodiment shown, observationwheel 22 comprises an outer ring 30 coupled to wheel hub 26 by aplurality of struts or spokes (and/or cables) 34, and a plurality ofgondolas 38 coupled to ring 30. In the embodiment shown, ring 30comprises dual ring members spaced apart and coupled together by aplurality of lateral members. Similarly, in the embodiment shown, wheelhub 26 comprises dual circular rail members (e.g., each having anI-shaped cross-sectional shape) that are spaced apart as illustrated. Inthe some embodiments, each of towers 14 a and 14 b has a base 42 a and42 b, respectively, and a height of at least 200 feet above a groundlevel at each base, and observation wheel 22 has a transverse dimensionof at least 400 feet (e.g., a diameter of 500 feet). In otherembodiments, one of towers 14 a and 14 b may be omitted such that towerhub 18 is cantilevered from a single hub. Towers 14 a and 14 b and/ortower hub 18 can, for example, comprise concrete and/or steel, andobservation wheel 22 can comprise steel and/or any of various otherhigh-strength metallic alloys.

Referring now to FIGS. 5-7B; FIGS. 5 and 6 depict fragmentary views ofsystem 10 showing tower hub 18, wheel hub 26, and a bearing subsystem 46between the tower hub and the wheel hub in more detail; and FIGS. 7A-7Bdepict a bearing assembly 50 of the bearing subsystem. In thisembodiment, bearing system 46 includes a plurality of roller bearings 54disposed between tower hub 18 and wheel hub 26 to rotatably supportobservation wheel 22 relative to the tower (and tower hub 26), theroller bearings each having a transverse dimension (e.g. diameter) thatis less than one quarter of the transverse dimension of the wheel hub.In the embodiment shown, each bearing assembly 50 includes a rollerbearing 54 and a bearing mount 58. More particularly, in thisembodiment, each bearing mount 58 has a first end 62 coupled in fixedrelation to tower hub 18 and a second end 66 rotatably coupled to theroller bearing 54 (e.g., via an axle or pair of stub axles, asillustrated in FIG. 7B). In this embodiment, roller bearing 54 has adiameter of between 0.5 and 5 feet (e.g., 4 feet). In the embodimentshown, each bearing assembly 50 can be independently sealed. Forexample, where roller bearing 54 is coupled to bearing mount 58 by asingle axle that extends through the roller bearing, grease can bedisposed between the roller bearing and the axle and can be retained byseals coupled to the roller bearing on opposite sides of the rollerbearing. As another example, where the roller bearing is coupled to thebearing mount by stub axles on either side of the roller bearing, greasecan be disposed between the stub axles and the bearing mount andretained by seals coupled to the bearing mount on opposite sides of theroller bearing. In other embodiment, some or all of bearing mounts 58may be affixed to the wheel hub. Roller bearings 54 and/or bearingmounts 58 can comprise, for example, steel and/or any of various otherhigh-strength metallic alloys. Roller mounts 58 can also, in someembodiments, comprise concrete. Each individual roller bearing 54 may becovered with an elastomeric layer (or “spring pad”), which may beconfigured to function as an independent suspension for each rollerbearing.

In some embodiments, an external diameter of the tower hub differs froman external diameter of the wheel hub by 4 feet or more. For example, inthe embodiment shown, the inner diameter of wheel hub 26 is about 10feet greater than the outer diameter of the portion of tower hub 18around which wheel hub 26 is configured to rotate. In this example, theradial gap between the tower hub and the wheel hub at any given point istherefore 5 feet, such that the overall height of each bearing assembly50 is 5 feet.

The present embodiments also offer additional benefits relative toconventional large-scale observation wheel attractions, which aretypically limited in the external wind forces they can withstand duringa storm or other wind event. The London Eye and subsequent wheels, suchas the Singapore Flyer and the Star of Nanchang, for example, containtwo, large, self-contained, sealed-axle rolling element bearings in thecenter hub of the wheel, which require a giant seal to encompass thebearing in order to exclude contamination and hold in lubricant. Whenutilizing large bearings in an observation wheel, the fact thathigh-grade metallurgical components can only be produced to a certainsize while still maintaining quality becomes a constraint on the overallsize of the attraction in high-wind cities. The present embodiments witha plurality of smaller, independently sealed bearing elements allow forthe operation of extremely large pieces while negating the need for alarge bearing and a large seal to encompass that bearing. For example,the embodiment of system 10 depicted in FIGS. 1-4, includesapproximately 80 smaller, independently sealed bearing assemblies 50,reducing and/or eliminating many if not all of the size constraintstypically associated with larger bearings. The relatively larger towerhub 18, in combination with the plurality of smaller bearings, makesconstruction of larger-scale observation wheels technically feasible byimproving the manufacturability and durability of the bearingcomponents, as well as improving the wind-loads that the system is ableto ensure. For example, in system 10 the outer diameter of tower hub 18of 80 feet aids in distributing high wind loads and results in astructurally beneficial ratio of the dimensions of the tower hub (and ofthe wheel hub) relative to the length of the spokes of the wheel.

As illustrated in FIGS. 8A and 8B, in the depicted embodiment of system10, the large-diameter (80 feet) of tower hub 18 also provides up to20,000 square feet or more of unique event space within the tower hub—afeature not available due to the bearing design in conventionalobservation wheels. In this embodiment, tower hub 18 includes acylindrical steel outer shell 100 supported by a plurality of circularsteel girders 104 disposed within shell 100. In this embodiment, shell100 includes a plurality of openings 108 through which beams 112 (e.g.,steel and/or pre-stressed concrete beams) can extend to support (e.g.,concrete) floors 116, as shown. In this embodiment, tower hub 18 furtherincludes and is supported by beams 120 that extend between towers 14 aand 14 b, and through shell 100. A plurality of vertical columns 124 canfurther support the structural integrity of tower hub 18 which functionsas an inner compression ring that is compressed by forces imparted onthe roller bearings by the inner surfaces of wheel hub 26, which acts asan outer race beam. In some embodiments, the resulting space within thetower hub can include several levels of observation decks with interiorand exterior space for visitors separated by glass windows. In otherembodiments, shell 100 can comprise concrete.

Of course, system 10 also includes a robust (e.g., concrete) foundation(not shown), especially where installed in areas with high winds (e.g.,Miami, where it would be subject to hurricane-force wind loads). Thefoundation may, for example, include drilled foundation piers extendingbelow the ground surface. Towers 14 a and 14 b cooperate with thefoundation to control and absorb high wind loads. These towers alsoprovide access to the tower hub with stairways (e.g., extending upthrough the center of one or both towers) and/or elevators (e.g.,extending up along a peripheral portion of the tower). The towers may,for example, be constructed or built by way of slip-formed concrete andcan be configured, as shown, to provide a relatively narrow base(relative to the diameter of the observation wheel) which may bevaluable in a congested city environment.

In some embodiments, a unique quadrant truss arrangement may be used inconstructing and erecting observation wheel 22 that is more efficientthan methods utilized on past observation wheel structures. Inparticular, spokes 34 can be erected and coupled to wheel hub 26 onespoke at a time with the respective spoke hanging down between thetowers (14 a and 14 b) and then the spoke can be jacked or pulled up asthe wheel hub is rotated a subsequent spoke is erected and coupled tothe wheel hub, thereby reducing the need for full height cranes (e.g.,cranes that are as tall as the full observation wheel.

In the embodiment shown, observation wheel 22 is configured to beoperated (rotated) with a traction wheel drive system, located betweentower hub 18 and wheel hub 26 (e.g., in place of or between two hubassemblies 50). One or more motor-driven wheels (e.g., steel orurethane-covered wheels) can be coupled to a motor that is fixed toeither of the tower hub or wheel hub and driven in contact the other ofthe tower hub or wheel hub. For example, it will generally be moreefficient to fix the motor relative to the tower hub so the mass of themotor need not be driven along with the rest of the observation wheel.These driven wheels may, for example, be driven by electric motorscoupled to gear reducers that drive a main gear attached to the wheel.

In some embodiments, system 10 also includes a secondary drive system(e.g., within one or both of bases 42 a and 42 b) that can applyrotational force to the observation wheel at the wheel's outer ring 30)using similar steel and/or urethane-covered traction wheels driven bygear-head electric motors. Such a secondary drive system can alsoprovide an emergence egress system for rotating observation wheel 22 toevacuate riders in case the primary drive system fails.

In some embodiments, system 10 can include a plurality of solar cellsdisposed on towers 14 a and 14 b, bases 42 a and 42 b, and/orobservation wheel 22. In some embodiments, such solar cells (andcorresponding storage batteries, if included) can provide a majority (ifnot all) of the energy needed to rotate the observation wheel (e.g., atleast during times of balanced or substantially steady-stateoperation—at which the rolling friction is relatively minimal due toimproved bearing system 46).

The above specification and examples provide a complete description ofthe structure and use of illustrative embodiments. Although certainembodiments have been described above with a certain degree ofparticularity, or with reference to one or more individual embodiments,those skilled in the art could make numerous alterations to thedisclosed embodiments without departing from the scope of thisinvention. As such, the various illustrative embodiments of the methodsand systems are not intended to be limited to the particular formsdisclosed. Rather, they include all modifications and alternativesfalling within the scope of the claims, and embodiments other than theone shown may include some or all of the features of the depictedembodiment. For example, elements may be omitted or combined as aunitary structure, and/or connections may be substituted. Further, whereappropriate, aspects of any of the examples described above may becombined with aspects of any of the other examples described to formfurther examples having comparable or different properties and/orfunctions, and addressing the same or different problems. Similarly, itwill be understood that the benefits and advantages described above mayrelate to one embodiment or may relate to several embodiments.

The claims are not intended to include, and should not be interpreted toinclude, means-plus- or step-plus-function limitations, unless such alimitation is explicitly recited in a given claim using the phrase(s)“means for” or “step for,” respectively.

1. A system comprising: a tower; a tower hub coupled to the tower andhaving a transverse dimension of at least 50 feet; an observation wheelrotatably coupled to the tower and having a central wheel hub; aplurality of roller bearings disposed between the tower hub and thewheel hub to rotatably support the observation wheel relative to thestructure, the roller bearings each having a diameter that is less thanone quarter of the transverse dimension of the wheel hub.
 2. The systemof claim 1, where the tower includes a base and a height of at least 200feet above a ground level at the base, and the observation wheel havinga transverse dimension of at least 400 feet.
 3. The system of claim 2,where the tower is a first tower, the system further comprising: asecond tower spaced apart from the first tower and coupled to the towerhub; where the tower hub extends between the first and second towers. 4.The system of claim 1, further comprising: a plurality of bearing mountseach coupled to a different one of the roller bearings.
 5. The system ofclaim 4, where the plurality of bearing mounts each has a first endcoupled in fixed relation to the tower hub and a second end rotatablycoupled to the respective roller bearing.
 6. The system of claim 5,where the wheel hub has a first diameter, the tower hub has a seconddiameter that is smaller than the first diameter, and the wheel hub isconfigured to rotate around the tower hub.
 7. The system of claim 1,where each of the plurality of roller bearings has a diameter of between0.5 and 5 feet.
 8. The system of claim 7, where the diameter of thetower hub differs from the diameter of the wheel hub by 4 feet or more.9. The system of claim 8, where the diameter of the tower hub is greaterthan 70 feet.
 10. The system of claim 1, where each of the plurality ofroller bearings is independently sealed.
 11. A method comprising:disposing a plurality of bearings between a tower hub and an observationwheel rotatably coupled to the tower, the tower hub coupled to a towerand having a transverse dimension of at least 50 feet, and theobservation wheel having a central wheel hub; where the roller bearingsare disposed between the tower hub and the wheel hub to rotatablysupport the observation wheel relative to the structure, the rollerbearings each having a diameter that is less than one quarter of thetransverse dimension of the wheel hub.
 12. The method of claim 11, wherethe tower includes a base and a height of at least 200 feet above aground level at the base, and the observation wheel having a transversedimension of at least 400 feet.
 13. The method of claim 12, where thetower is a first tower, a second tower is spaced apart from the firsttower and coupled to the tower hub, and the tower hub extends betweenthe first and second towers.
 14. The method of claim 11, where aplurality of bearing mounts are each coupled to a different one of theroller bearings.
 15. The method of claim 14, where the plurality ofbearing mounts each has a first end and a second end rotatably coupledto the respective roller bearing, and disposing the roller bearingscomprises coupling the first end of each roller bearing in fixedrelation to the tower hub.
 16. The method of claim 15, where the wheelhub has a first diameter, the tower hub has a second diameter that issmaller than the first diameter, and the wheel hub is configured torotate around the tower hub.
 17. The method of claim 11, where each ofthe plurality of bearing elements has a diameter of between 0.5 and 5feet.
 18. The method of claim 17, where the diameter of the tower hubdiffers from the diameter of the wheel hub by 4 feet or more.
 19. Themethod of claim 18, where the diameter of the tower hub is greater than70 feet.
 20. The method of claim 11, where each of the plurality ofroller bearings is independently sealed.